106961-6140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069616140 1156030210

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-6140 1069616140

ISUZU 1156030210 1156030210

Service parts 106961-6140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9560

3. GOVERNOR 105487-6890

4. SUPPLY PUMP 105237-4420

5. AUTOM. ADVANCE MECHANIS 105687-0500

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder 1-15300-204-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106961-6140 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-6140 1069616140

ISUZU 1156030210 1156030210

Zexel num

Bosch num

Firm num

Name

106961-6140
106961-6141

1156030210 ISUZU

INJECTION-PUMP ASSEMBLY
10PD1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve (drive side) 134424-4020

Overflow valve opening pressure (drive side) kPa 255 221 289

Overflow valve opening pressure (drive side) kgf/cm2 2.6 2.25 2.95

Overflow valve (governor side) 134424-2720

Overflow valve opening pressure (governor side) kPa 255 221 289

Overflow valve opening pressure (governor side) kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-6- 5-4-3-10 -9-2

Pre-stroke mm 4.4 4.37 4.43

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 7.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 100 98.5 101.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 112 108 116

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 109 107 111

Fixing the lever *

Injection quantity adjustment_04

Adjusting point -

Rack position 4.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 13.5 12.2 14.8

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 620--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 570

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 850+-30

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1120

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Damper spring setting
----------
RT=0.8 TH=2.9mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=5.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=51deg+-5deg b=64deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side) (3)B.T.D.C.: aa (set timing) (4)-
----------
aa=10deg
----------
a=(180deg)